Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Model Code Range:
Specific chassis codes may vary within these years; manual covers all 200 EXC variants.
Vehicle Segment:
Enduro Motorcycle
Target Audience:
Off-road enthusiasts, trail riders, and competitive enduro riders seeking performance and durability.
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (two-stroke era).
Engine Type:
Aggressive two-stroke power delivery, lightweight design.
Chassis:
Strong chromoly steel frame, WP suspension components.
Off Road Capability:
Designed for demanding off-road conditions, including trails, hard enduro, and motocross.
Engine:
Complete engine overhaul, disassembly, assembly, tuning, and diagnostics for the 200cc two-stroke engine.
Transmission:
Clutch, gearbox (including gear inspection, replacement, and lubrication), and final drive maintenance.
Fuel System:
Carburetor (Mikuni VM28 or similar), fuel tank, fuel lines, and petcock maintenance and tuning.
Ignition System:
CDI ignition, spark plug specifications, timing adjustments, and troubleshooting.
Cooling System:
Liquid cooling system, radiator, hoses, water pump maintenance, and coolant specifications.
Exhaust System:
Expansion chamber, silencer inspection, and repacking procedures.
Suspension:
Front forks (WP USD), rear shock absorber (WP), suspension adjustments, oil changes, seal replacement, and general service.
Brakes:
Hydraulic disc brakes (front and rear), caliper service, pad replacement, fluid bleeding, master cylinder maintenance, and rotor specifications.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, switchgear, and basic electrical troubleshooting.
Frame And Bodywork:
Frame inspection, handlebar and control adjustments, seat removal, body panel repair and fitting.
Preventive Maintenance:
Detailed schedules for oil changes, filter replacements, chain adjustment, and general inspections.
Troubleshooting:
Systematic guides for diagnosing common problems with the engine, transmission, electrical system, and chassis.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Rebuilds:
Comprehensive guides for engine and transmission rebuilds, including torque specifications and clearances.
Technical Data Charts:
Inclusion of specification tables, torque values, fluid capacities, and electrical resistance values.
Depth:
Advanced diagnostics and detailed repair procedures suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Tools:
While specific diagnostic tool mentions might be limited, the manual provides the fundamental knowledge for diagnosing mechanical and electrical issues.
Engine Type:
Two-stroke, liquid-cooled, single-cylinder
Displacement:
Approximately 193 cc (bore x stroke typically around 62.5 mm x 64 mm)
Bore X Stroke:
Refer to manual for exact specifications, typically 62.5 x 64 mm
Compression Ratio:
Varies by year and specific tuning, typically around 8.5:1 to 9.5:1 for stock configuration.
Horsepower:
Estimated 35-40 HP (stock configuration), power output can vary significantly with tuning and modifications.
Torque:
Refer to manual for exact specifications; known for strong low-to-mid range power.
Carburetor Type:
Typically Mikuni VM28 or similar, with specific jetting and tuning recommendations in the manual.
Fuel Type:
Leaded or unleaded gasoline with appropriate octane rating, premixed with two-stroke oil.
Oil Mixture Ratio:
Refer to manual, typically 30:1 or 40:1, depending on oil type and riding conditions.
Engine Oil Type:
Specific two-stroke engine oil required; refer to manual for recommended grades and specifications.
Engine Oil Change:
Refer to manual, typically every 15-20 hours of riding for 2-stroke premix.
Air Filter Cleaning:
Regularly, often every few rides or after dusty conditions; detailed cleaning and oiling procedures in manual.
Spark Plug Replacement:
As per manual recommendations, typically every 20-40 hours of riding depending on plug type and condition.
Suspension Service:
Fork oil and seal replacement typically every 40-60 hours; rear shock service as per manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors; specific KTM recommendations should be followed.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid; refer to manual for precise specification.
Transmission Oil Type:
Dedicated 2-stroke engine oil for premix (not gearbox oil); manual specifies suitable types.
Power Valve Sticking:
Common in 2-stroke engines, requires periodic cleaning and lubrication. Manual covers disassembly and service.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes; manual provides comprehensive tuning guidance.
Suspension Seals:
Wear on fork seals can lead to leaks; manual details seal replacement procedures.
Clutch Wear:
Clutch plates can wear over time, requiring adjustment or replacement. Manual provides clutch service details.
Brand Focus:
KTM is renowned for its off-road racing heritage, consistently producing high-performance dirt bikes.
Platform:
The 200 EXC represents a lineage of KTM's successful EXC enduro models, known for their aggressive power and nimble handling.
Key Changes:
Minor updates and refinements throughout the 1999-2010 period, focusing on suspension tuning, engine performance, and component durability.
Manufacturing Location:
Austria (KTM's primary manufacturing hub)
Brand Recognition:
KTM consistently receives accolades for its performance-oriented off-road motorcycles.
Off Road Capability Ratings:
Praised by off-road publications for its agility, power, and suspension performance during its production run.
Manufacturing Standards:
Built to KTM's stringent European manufacturing standards.
